ecosine max passive harmonic filters · user and installation manual ecosine max . schaffner.com...

Schaffner Group | Nordstrasse 11e | 4542 Luterbach | Switzerland T +41 32 681 66 26 | [email protected] | www.schaffner.com

User and Installation Manual Ecosine max Passive Harmonic Filters

Ecosine max FN 3470/FN 3471 (50 Hz) for 380–415 VAC FN 3480/FN 3481 (50 Hz) for 440–480 VAC FN 3472/FN 3473 (60 Hz) for 380–415 VAC English version (original instructions) FN 3482/FN 3483 (60 Hz) for 440–480 VAC

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Copyright ©2020 Schaffner International Ltd. All Rights Reserved. All rights of this User and Installation Manual (“Manual”) including but not limited to the contents, information, and figures are solely owned and reserved by Schaffner International Ltd. (“Schaffner”). The Manual can only be applied to the oper-ation or the use of ecosine filter. Any disposition, duplication, dissemination, reproduction, modification, translation, extraction, or usage of this Manual in whole or in part is prohibited without the prior written permission of Schaffner. Given that Schaffner will continuously improve and develop the product, changes may be made to the information in this Manual at any time without obligation to notify any person of such revision or changes. Schaffner will make all possible efforts to secure the accuracy and the integrity of this Manual. Schaffner disclaims any kinds or forms of warranty, guarantee, or undertak-ing, either expressly or implicitly, including but not limited to the completeness, faultlessness, accuracy, non-infringement, merchantability or fitness for a particular purpose of the Manual.

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Schaffner Group User and Installation Manual Ecosine max

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Revision: 02 (October 2020)

The most current edition of this document (PDF format) and official translations can be obtained from your contact of the Schaffner organization or online at schaffner.com

Other technical documentation of our products is also available in the download area of our website schaffner.com/downloads

Document name:

User and Installation Manual ecosine max Rev02.pdf

Valid for ecosine version:

FN 3470/FN 3471 (50 Hz) for 380–415 VAC FN 3480/FN 3481 (50 Hz) for 440–480 VAC FN 3472/FN 3473 (60 Hz) for 380–415 VAC FN 3482/FN 3483 (60 Hz) for 440–480 VAC Version history

Revision Date Description

01 February 2020 Initial version

02 October 2020 Tables formatting in the whole document (table pasted as picture from datasheet were converted to real editable table to allow a better trans-lation of the document and possible future updates)

Typo corrections. Better harmonization of technical terms within the document and between products line

Sections 3.1 to 3.4 specification of insulation class SCH-155(F) re-moved (mistake from document), all versions use insulation class SCH-200(N)

Section 3.6.1 Table 20 addition of cross section in AWG/kcmil and up-dated according to UL requirement

Section 3.6.2 added for trap disconnect jumper terminals cables re-quirement

Section 3.6.3 added - auxiliary cables requirement

Section 3.8 added – thermal switch specifications

Section 3.9 Table 24 addition of part for reference cabinets (line 6 to 8)

Section 3.10 new requirement for cooling, including air flow, air inlet and additional pictures for proper opening requirement at the bottom and back of the cabinet

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i. Ecosine max passive harmonic filter Ecosine max product highlights

Schaffner ecosine max passive harmonic filters are configurable products which provide a tailored so-lution to each specific problem of current harmonics mitigation of 3-phase non-linear loads.

The eight product lines, FN 3470/FN 3471, FN 3480/FN 3481, FN 3472/FN 3473 and FN 3482/FN 3483 are applicable for low voltage 50 Hz and 60 Hz systems and they are particularly suitable for AC and DC motor drives, battery chargers and other power electronics applications with 6-pulse front-end rectifiers.

Ecosine max passive harmonic filter technology represents an evolution of the previous generations of passive harmonic filters and introduces following aspects of novelty:

│ Ecosine max is designed for the most demanding harmonic mitigation tasks. Ecosine max filters FN 3470/71, FN 3472/73, FN 3480/81 and FN 3482/83 can be applied to drives with or without DC-link choke present, different THDi @ rated power can be achieved, as shown in the following table. The new generation ecosine max filters guarantee compliance with the toughest requirement of IEEE-519 and other stringent international power quality standards.

Table 1 Ecosine max product variants and performance

FN3470 FN3471 FN3480 FN3481 FN3472 FN3473 FN3482 FN3483

Grid frequency 50Hz 60Hz

Nominal operating voltage 3x380-415VAC 3x440-480VAC 3x380-415VAC 3x440-480VAC

For 6-pulse diode rectifier

without DC-link choke


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ii. Performance Guarantee By selecting and installing the appropriate ecosine max passive harmonic filter in a variable frequency AC drive application (variable speed drive application) within our published technical specifications, we guarantee that the input current distortion will be less than or equal to 5% THDi for standard ecosine max series filters at rated power. Ecosine max filters can also provide similar performance in other drive applications such as constant torque, DC drives or other phase controlled rectifiers, e.g. SCR drives, but actual THDi levels can vary by load and/or speed and/or firing angle of thyristors and there-fore cannot be guaranteed. Consult Schaffner or our local representative for assistance when applying ecosine filters on these types of equipment.

iii. Minimum system Requirements The guaranteed performance levels of this filter will be achieved when the following system conditions are met:

| Type of load: Any 3-phase equipment with front-end six-pulse diode rectifier, with or without DC-link choke

| Type of source: 3-phase power line without neutral | Line impedance:


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v. General Safety Notes and Installation Guidelines (Cautions and Warnings)



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Content

i. Ecosine max passive harmonic filter ........................................................................................... 3

ii. Performance Guarantee ................................................................................................................. 4

iii. Minimum system Requirements................................................................................................ 4

iv. Important user notice ................................................................................................................. 4

v. General Safety Notes and Installation Guidelines (Cautions and Warnings) .......................... 5

1 Ecosine max passive harmonic filter designation ............................................ 9

1.1 Distinguishing between FN 3470/FN 3471, FN 3480/FN 3481, FN 3472/FN 3473 and FN 3482/FN 3483 .......................................................................................................................................... 9

1.2 Explanation of ecosine max designation ............................................................................... 10

2 Filter selection ................................................................................................... 12

2.1 Filter selection tables FN 3470/FN 3471 (50 Hz, 3×380 … 415 VAC) .................................... 14

2.2 Filter selection table FN 3480/FN 3481 (50 Hz, 3×440 … 480 VAC) ...................................... 16



3 Filter description ................................................................................................ 22

3.1 General electrical specifications FN 3470/FN 3471 (50 Hz filters) ....................................... 22




3.5 Additional electrical specifications ........................................................................................ 26

3.6 Cable cross-section requirement ............................................................................................ 26

3.6.1 Power terminals ................................................................................................................... 26

3.6.2 Trap disconnect jumper terminals ....................................................................................... 29

3.6.3 Auxiliary terminals ............................................................................................................... 29

3.7 Earth terminals screw and torque ........................................................................................... 30

3.8 Thermal protection switch specifications .............................................................................. 30



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3.9 Cabinet specifications .............................................................................................................. 30

3.10 Cooling requirement ............................................................................................................. 32

3.10.1 Additional requirement for cooling ....................................................................................... 33

3.11 Mechanical frame sizes ........................................................................................................ 36

3.12 Ecosine max passive harmonic filter footprint .................................................................. 37

3.13 Filter performance ................................................................................................................. 39

3.14 Functional diagram ............................................................................................................... 41

3.14.1 Filter configuration ............................................................................................................... 41

3.14.2 Filter configuration -E0XXJXX ............................................................................................. 42

4 Ecosine max harmonic filter schematics and working principle ................... 43

5 Filter appearance and elements ....................................................................... 44

5.1 Mechanical design of FN3470/80/72/82 (with load choke present) ...................................... 44

5.2 Mechanical design of FN3471/81/73/83 (without load choke present) ................................ 45

6 Performance estimation using SchaffnerPQS ................................................ 47

7 Filter application ................................................................................................ 48

8 Filter installation ................................................................................................ 50

8.1 Step 1: Visual inspection ......................................................................................................... 50

8.2 Step 2: Mounting ....................................................................................................................... 51

8.2.1 Fixation ................................................................................................................................ 52

8.2.2 Screws and bolts selection .................................................................................................. 53

8.2.3 Filter placement: .................................................................................................................. 53

8.3 Step 3: Wiring ............................................................................................................................ 55

8.3.1 Verify safe disconnection of all line side power ................................................................... 55

8.3.2 Carefully connect protective earth (PE) cable to adequate earth potential close to ecosine filter 55

8.3.3 Connect PE cable of ecosine filter ...................................................................................... 55

8.3.4 Connect ecosine main terminals to the respective phase on the line and load/rectifier ..... 56

8.3.5 Install external capacitive current control ............................................................................ 57



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8.3.6 Connect monitor switch TS- TS’ .......................................................................................... 57

8.3.7 Connect auxiliary switch AS- AS’ ........................................................................................ 58

8.3.8 Install and connect the switch remote operator ................................................................... 59

8.3.9 Fuses ................................................................................................................................... 60

9 Filter maintenance ............................................................................................. 62

9.1 Maintenance schedule ............................................................................................................. 62

9.2 Power capacitors ...................................................................................................................... 63

9.2.1 Storage of capacitors ........................................................................................................... 63

9.3 Electrical connections .............................................................................................................. 63

10 Trap circuit disconnect .................................................................................. 64

11 Troubleshooting ............................................................................................. 65



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1 Ecosine max passive harmonic filter designation 1.1 Distinguishing between FN 3470/FN 3471, FN 3480/FN 3481, FN 3472/FN 3473 and FN 3482/FN 3483 The main difference between FN3470 (FN3472, FN3480 FN3482) and FN3471 (FN3473, FN3481, FN3483) is the filter configuration, which is clearly shown in Figure 1 and Figure 2 below. FN3470, FN3472, FN3480 and FN3482 filters contain 3 chokes, which enables them to handle the most tough harmonic mitigation task and to achieve very high performance (5% THDi). FN3471, FN3473, FN3481 and FN3483 contain 2 chokes, they are optimal choice if the THDi requirement is lower or for drives with DC-link choke present. The performance of all product variants at different drive setup can be found in Table 1.

Figure 1 Filter configuration of FN3470, FN3472, FN3480 and FN3482

Figure 2 Filter configurations for FN3471, FN3473, FN3481 and FN3483



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1.2 Explanation of ecosine max designation Ecosine max is part of the new generation of Schaffner passive harmonic filter. Starting from Schaffner ecosine evo series, a designation system, which contains of 4 sections connected with ‘-’ was intro-duced. Ecosine max series, due to its open frame design aimed at cabinet installation, is not offering all options that could be found in ecosine evo series but share the same designation system with an X for unavailable options.

Figure 3 Ecosine max designation

| The first part of the designation ‘FN 34nn-xxx-yyy-_ _ _ _ _ _ _’ distinguishes between the eight ecosine max filter series.

Table 2 operating frequency and nominal voltage per filter type

FN 3470 FN 3471 FN 3480 FN 3481 FN 3472 FN 3473 FN 3482 FN 3483

Operating frequency 50 Hz 50 Hz 60 Hz 60 Hz

Nominal operating voltage 3x 380 to 415 VAC 3x 440 to 480 VAC 3x 380 to 415 VAC 3x 440 to 480 VAC

| The second part of the designation ‘FN 34nn-xxx-yyy-_ _ _ _ _ _ _’ indicates the motor drive power rating, in kW for 50 Hz filters and in HP for 60 Hz filters. Please note that ecosine max filters are not using current rating in the designation.

| The third part of the designation ‘FN 34nn-xxx-yyy-_ _ _ _ _ _ _’ indicates the power terminal type. For ecosine max all filters are equipped with busbar terminals (-99).

| |The fourth part of the designation ‘FN 34nn-xxx-yyy- E0XX_XX’ contains seven slots. This designation format is shared with ecosine evo series, however the ecosine max series doesn’t offer all the options of evo series, the only relevant option is the 5th slot, designating the pres-ence of a switch (S) or a trap disconnect jumper module (J) for installing a switch provided by customer themselves.

| Schaffner offers Power Quality Simulator SchaffnerPQS3 (pqs.schaffner.com) to select and verify the most suitable ecosine max filter for your application.

https://www.schaffner.com/https://pqs.schaffner.com/


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Examples of ecosine max filter designations:

FN 3470-315-99-E0XXSXX: Filter for 50 Hz, 380–415 V AC grid, motor drive power rating 315kW, open frame (IP 00), filter contains trap disconnect switch module. Filter is expected to achieve 5% THDi for drives without DC-link choke, or 3.5% THDi for drives with 4% DC-link choke.

FN 3481-400-99-E0XXJXX: Filter for 50 Hz, 440–480 V AC grid, motor drive power rating 400kW, open frame (IP 00), filter contains trap disconnect jumper module. Filter is expected to achieve 8% THDi for drives without DC-link choke, or 5% THDi for drives with 4% DC-link choke.

FN 3482-500-99-E0XXSXX: Filter for 60 Hz, 440–480 V AC grid, motor drive power rating 500HP, open frame (IP 00), filter contains trap disconnect switch module. Filter is expected to achieve 5% THDi for drives without DC-link choke, or 3.5% THDi for drives with 4% DC-link choke.



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2 Filter selection Ecosine max passive harmonic filters need to be carefully selected and configured in order to enjoy maximum benefits. Schaffner advices to verify the selection by using the Schaffner Power Quality Sim-ulator tool SchaffnerPQS3, available at pqs.schaffner.com.

Step 1: Grid frequency

Determine, whether the system in consideration will be operated in a 50 Hz or 60 Hz electricity grid, and select the corresponding filter series according to the following table:

50 Hz grid Europe, Middle East, parts of Asia, parts of South America FN 3470/FN 3471

FN 3480/FN 3481

60 Hz grid North and Central America, parts of Asia, parts of South America FN 3472/FN 3473

FN 3482/FN 3483

Note: a 50 Hz filter will not provide satisfying harmonics mitigation in a 60 Hz grid, and vice versa.

Step 2: Grid voltage

Verify that the grid configuration is suitable for standard ecosine max passive harmonic filters accord-ing to the following table:

50 Hz grid Nominal voltage 380–415 V AC TN, TT, IT configuration




Step 3: Rectifier type, presence of DC-link choke in drive

Refer Table 1 for filter performance.

Step 4: Rectifier/Drive input power

The individual filter must be selected with respect to the rectifier/motor drive input power in kW respec-tively in HP. It is important to match rated filter power as close as possible with the effective input power of the rectifier/drive.

Note that if the rectifier/drive is being operated very close to its rated power, then the filter can be se-lected by the motor drive’s nominal power rating. However, if the drive will be operated e.g. at only 66% of its rated power, then a smaller filter should be selected in order to get maximum harmonics mitigation performance and the optimum in terms of cost, size, and weight. In that case the customer is responsible to ensure that ecosine passive harmonic filter will be operated within specification. This is particularly important in terms of overload.



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Please refer to the following examples:

Example 1: Power line rating: 400 V, 50 Hz Drive rating: 380–500 V, 50–60 Hz, 355 kW, 727 A, B6-diode rectifier without DC-link choke Required THDi @ rated power: 5% Planned rectifier/drive input real power: 355kW (100% of drive rating) Recommended filter: Type FN 3470-355-99 Example 2: Power line rating: 400 V, 50 Hz Drive rating: 380–500 V, 50–60 Hz, 355 kW, 559 A, B6-diode rectifier with an 4% DC-link choke Planned rectifier/drive input real power: 355 kW (100% of drive rating) Required THDi @ rated power: 5% Recommended filter: Type FN 3471-355-99 Example 3: Power line rating: 480 V, 50 Hz Drive rating: 440–480 V, 50–60 Hz, 400 kW, 700 A, B6-diode rectifier without DC-link choke Planned rectifier/drive input real power: 400kW (100% of drive rating) Required THDi @ rated power: 10% Recommended filter: Type FN 3481-400-99 Example 4: Power line rating: 480 V, 60 Hz Drive rating: 380–500 V, 50–60 Hz, 400 HP, 537 A, diode rectifier Planned rectifier/drive input real power: 400 HP (100% of drive rating) Required THDi @ rated power: 10% Recommended filter: Type FN 3483-400-99 Oversizing of passive harmonic filters is not recommended because of the inherent lower harmonic mitigation per-formance at partial load as well as higher cost, size, and weight. Please refer to sections 2.1 to 2.4 for proper filter selection.



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2.1 Filter selection tables FN 3470/FN 3471 (50 Hz, 3×380 … 415 VAC) Table 3 FN 3470 filter selection table for models with circuit breaker

Filter Rated load power @ 400V /50 Hz

Motor drive input current

Rated filter input cur-rent

Typi-cal power losses @ 40°C

Circuit breaker rated current

Weight

Termi-nal

Frame size

[kW] [Arms] [Arms] [W] [A] [kg]

FN 3470-250-99-E0XXSXX

250 435 376 3029 250 270 Busbar S10

FN 3470-315-99-E0XXSXX

315 655 475 3295 250 295 Busbar S10

FN 3470-355-99-E0XXSXX

355 727 538 3527 300 320 Busbar S12

FN 3470-400-99-E0XXSXX

400 808 608 4617 400 426 Busbar L10

FN 3470-500-99-E0XXSXX

500 985 766 4475 400 510 Busbar L12

*Motor drive input current without harmonic filter.

Table 4 FN 3470 filter selection table for models with trap disconnect jumper





Weight Terminal Frame size

[kW] [Arms] [Arms] [W] [kg]

FN 3470-250-99-E0XXJXX

250 435 376 3029 270 Busbar S10

FN 3470-315-99-E0XXJXX

315 655 475 3295 295 Busbar S10

FN 3470-355-99-E0XXJXX

355 727 538 3527 320 Busbar S12

FN 3470-400-99-E0XXJXX

400 808 608 4617 426 Busbar L10

FN 3470-500-99-E0XXJXX

500 985 766 4475 510 Busbar L12

*Motor drive input current without harmonic filters.



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Table 5 FN 3471 filter selection table for models with circuit breaker


Motor drive input cur-rent*


Re-quired Ldc for 5% THDi**



Weight Ter-minal

Frame size

[kW] [Arms] [Arms] [mH] [W] [A] [kg]

FN 3471-250-99-E0XXSXX

250 435 376 0.082 1974 250 240 Bus-bar

S08

FN 3471-315-99-E0XXSXX

315 655 475 0.065 2226 250 270 Bus-bar

S08

FN 3471-355-99-E0XXSXX

355 727 538 0.058 2346 300 292 Bus-bar

S08

FN 3471-400-99-E0XXSXX

400 808 608 0.051 3501 400 362 Bus-bar

L08

FN 3471-500-99-E0XXSXX

500 985 766 0.041 3195 400 410 Bus-bar

L08

*Motor drive input current without filter. **FN 3471 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN3471 is applied to drives without Ldc, while 5% THDi (@rated power) is achieved when there is a 4% Ldc pre-sent in the drive.






Typical power losses @ 40°C

Weight Termi-nal

Frame size

[kW] [Arms] [Arms] [mH] [W] [kg]

FN 3471-250-99-E0XXJXX

250 435 376 0.082 1974 240 Busbar S08

FN 3471-315-99-E0XXJXX

315 655 475 0.065 2226 270 Busbar S08

FN 3471-355-99-E0XXJXX

355 727 538 0.058 2346 292 Busbar S08

FN 3471-400-99-E0XXJXX

400 808 608 0.051 3501 362 Busbar L08

FN 3471-500-99-E0XXJXX

500 985 766 0.041 3195 410 Busbar L08

*Motor drive input current without filter. **FN 3471 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN3471 is applied to drives without Ldc, while 5% THDi (@rated power) is achieved when there is a 4% Ldc pre-sent in the drive.



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2.2 Filter selection table FN 3480/FN 3481 (50 Hz, 3×440 … 480 VAC) Table 7 FN 3480 filter selection table for models with circuit breaker






Weight

Termi-nal

Frame size


FN 3480-315-99-E0XXSXX

315 565 393 3278 250 270 Busbar S10

FN 3480-355-99-E0XXSXX

355 630 442 3343 250 328 Busbar S10

FN 3480-400-99-E0XXSXX

400 701 499 3584 300 366 Busbar S12

FN 3480-500-99-E0XXSXX

500 856 629 4356 400 385 Busbar L10

FN 3480-560-99-E0XXSXX

560 947 705 4536 400 410 Busbar L12









FN 3480-315-99-E0XXJXX

315 565 393 3278 270 Busbar S10

FN 3480-355-99-E0XXJXX

355 630 442 3343 328 Busbar S10

FN 3480-400-99-E0XXJXX

400 701 499 3584 366 Busbar S12

FN 3480-500-99-E0XXJXX

500 856 629 4356 385 Busbar L10

FN 3480-560-99-E0XXJXX

560 947 705 4536 410 Busbar L12




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Weight Ter-minal

Frame size


FN 3481-315-99-E0XXSXX

315 564 393 0.094 2223 250 250 Bus-bar

S08

FN 3481-355-99-E0XXSXX

355 630 444 0.083 2274 250 272 Bus-bar

S08

FN 3481-400-99-E0XXSXX

400 701 501 0.074 2403 300 288 Bus-bar

S08

FN 3481-500-99-E0XXSXX

500 856 630 0.059 3240 400 376 Bus-bar

L08

FN 3481-560-99-E0XXSXX

560 947 709 0.053 3256 400 385 Bus-bar

L08

* Motor drive input current without harmonic filter. ** FN 3481 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN3481 is applied to drives without Ldc, while 5% THDi (@ rated power) is achieved when there is a 4% Ldc pre-sent in the drive.







Weight Termi-nal

Frame size


FN 3481-315-99-E0XXJXX

315 564 393 0.094 2223 250 Busbar S08

FN 3481-355-99-E0XXJXX

355 630 444 0.083 2274 272 Busbar S08

FN 3481-400-99-E0XXJXX

400 701 501 0.074 2403 288 Busbar S08

FN 3481-500-99-E0XXJXX

500 856 630 0.059 3240 376 Busbar L08

FN 3481-560-99-E0XXJXX

560 947 709 0.053 3256 385 Busbar L08

* Motor drive input current without harmonic filter. ** FN 3481 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN3481 is applied to drives without Ldc, while 5% THDi (@ rated power) is achieved when there is a 4% Ldc pre-sent in the drive.



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Weight

Termi-nal

Frame size


FN3472-280-99-E0XXSXX

209 280 472 327 2832 200 245 540

FN3472-315-99-E0XXSXX

235 315 537 375 3200 200 270 595

FN3472-355-99-E0XXSXX

265 355 595 420 3451 250 295 650

FN3472-400-99-E0XXSXX

300 400 656 469 3404 250 320 705

FN3472-480-99-E0XXSXX

358 480 773 563 4173 300 385 849









FN3472-280-99-E0XXJXX

209 280 472 327 2832 245 540

FN3472-315-99-E0XXJXX

235 315 537 375 3200 270 595

FN3472-355-99-E0XXJXX

265 355 595 420 3451 295 650

FN3472-400-99-E0XXJXX

300 400 656 469 3404 320 705

FN3472-480-99-E0XXJXX

358 480 773 563 4173 385 849




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Weight Ter-minal

Frame size


FN3473-280-99-E0XXSXX

209 280 472 325 0.074 2085 200 220 485

FN3473-315-99-E0XXSXX

235 315 537 374 0.066 2145 200 245 540

FN3473-355-99-E0XXSXX

265 355 595 418 0.058 2382 250 270 595

FN3473-400-99-E0XXSXX

300 400 656 467 0.052 2223 250 295 650

FN3473-480-99-E0XXSXX

358 480 772 561 0.044 3057 300 360 794

* Motor drive input current without harmonic filter. ** FN 3473 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN 3473 is applied to drives without Ldc, while 5% THDi (@ rated power) is achieved when there is a 4% Ldc present in the drive.







Weight Termi-nal

Frame size


FN3473-280-99-E0XXJXX

209 280 472 325 0.074 2085 220 485

FN3473-315-99-E0XXJXX

235 315 537 374 0.066 2145 245 540

FN3473-355-99-E0XXJXX

265 355 595 418 0.058 2382 270 595

FN3473-400-99-E0XXJXX

300 400 656 467 0.052 2223 295 650

FN3473-480-99-E0XXJXX

358 480 772 561 0.044 3057 360 794

* Motor drive input current without harmonic filter. ** FN 3473 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN 3473 is applied to drives without Ldc, while 5% THDi (@ rated power) is achieved when there is a 4% Ldc present in the drive.



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Filter Rated load power@ 480

V/60 Hz

Motor drive input

cur-rent*

Rated filter

input cur-rent

Typical power losses

@ 40°C

Circuit breaker rated

cur-rent

Weight

Ter-mi-nal

Frame

size

[kW] [HP] [Arms] [Arms] [W] [A] [kg] [lbs]

FN 3482-350-99-E0XXSXX

260 350 472 327 2832 200 245 540 Bus-bar

S10

FN 3482-400-99-E0XXSXX

300 400 537 375 3200 200 270 595 Bus-bar

S10

FN 3482-450-99-E0XXSXX

335 450 595 420 3451 250 295 650 Bus-bar

S10

FN 3482-500-99-E0XXSXX

370 500 656 467 3404 250 320 705 Bus-bar

S12

FN 3482-600-99-E0XXSXX

450 600 773 563 4173 300 385 849 Bus-bar

L10



Filter Rated load power@ 480 V/60

Hz

Motor drive input

cur-rent*

Rated filter in-put cur-

rent

Typical power losses

@ 40°C

Weight

Termi-nal

Frame size

[kW] [HP] [Arms] [Arms] [W] [kg] [lbs]

FN 3482-350-99-E0XXJXX

260 350 472 327 2832 245 540 Busbar S10

FN 3482-400-99-E0XXJXX

300 400 537 375 3200 270 595 Busbar S10

FN 3482-450-99-E0XXJXX

335 450 595 420 3451 295 650 Busbar S10

FN 3482-500-99-E0XXJXX

370 500 656 467 3404 320 705 Busbar S12

FN 3482-600-99-E0XXJXX

450 600 773 563 4173 385 849 Busbar L10




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Filter Rated load power @ 480 V/60

Hz

Motor drive input

cur-rent*

Rated filter

input cur-rent

Re-quired

Ldc for 5% THDi**

Typi-cal

power losses

@ 40°C

Circuit breaker

rated current

Weight Ter-minal

Frame size

[kw] [HP] [Arms] [Arms] [mH] [W] [A] [kg] [lbs]

FN 3483-350-99-E0XXSXX

260 350 472 325 0.095 2085 200 220 485 Bus-bar

S08

FN 3483-400-99-E0XXSXX

300 400 537 374 0.082 2145 200 245 540 Bus-bar

S08

FN 3483-450-99-E0XXSXX

335 450 595 418 0.074 2382 250 270 595 Bus-bar

S08

FN 3483-500-99-E0XXSXX

370 500 656 467 0.066 2223 250 295 650 Bus-bar

S08

FN 3483-600-99-E0XXSXX

450 600 772 561 0.055 3057 300 360 794 Bus-bar

L08

*Motor drive input current without harmonic filter. ** FN 3483 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN3483 is applied to drives without Ldc, while 5% THDi (@ rated power is achieved when there is a 4% Ldc pre-sent in the drive.


Filter Rated load power @ 480 V/60

Hz

Motor drive input

cur-rent*

Rated filter

input cur-rent

Re-quired

Ldc for 5%

THDi**

Typi-cal

power losses

@ 40°C

Weight Termi-nal

Frame size

[kw] [HP] [Arms] [Arms] [mH] [W] [kg] [lbs]

FN 3483-350-99-E0XXJXX

260 350 472 325 0.095 2085 220 485 Busbar S08

FN 3483-400-99-E0XXJXX

300 400 537 374 0.082 2145 245 540 Busbar S08

FN 3483-450-99-E0XXJXX

335 450 595 418 0.074 2382 270 595 Busbar S08

FN 3483-500-99-E0XXJXX

370 500 656 467 0.066 2223 295 650 Busbar S08

FN 3483-600-99-E0XXJXX

450 600 772 561 0.055 3057 360 794 Busbar L08

*Motor drive input current without harmonic filter. ** FN 3483 filters can be applied for drives with and without Ldc. 8% THDi (@ rated power) is achieved when FN3483 is applied to drives without Ldc, while 5% THDi (@ rated power is achieved when there is a 4% Ldc pre-sent in the drive.



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3 Filter description 3.1 General electrical specifications FN 3470/FN 3471 (50 Hz filters)

Nominal operating voltage: 3x 380 to 415 V AC Voltage tolerance range: 3x 342 to 457 V AC Operating frequency: 50 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 250 to 500kW Total harmonic current distortion THDi: 2) 99% @ nominal line voltage and power Drive dc-link voltage: 3) -5% ~ +10% nominal VDC High potential test voltage: 4) P E 2520 VAC (1s) SCCR: 5) 100kA, fuses according UL class J or L Protection category: IP 00 Overvoltage category (acc. IEC 60664-1) III Pollution degree: PD3 (according to standard IEC 60664-1) Climatic class: 25/070/21 (IEC60068-1) Cooling: External cooling 6) Overload capability: 1.6x rated current for 1 minute, once per hour Capacitive current @ no load: 200,000 hours MTTR:


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3.2 General electrical specifications FN 3480/FN 3481 (50 Hz filters)

Nominal operating voltage: 3x 440 to 480 V AC Voltage tolerance range: 3x 396 to 528 V AC Operating frequency: 50 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 315 to 560kW Total harmonic current distortion THDi: 2) 99% @ nominal line voltage and power Drive dc-link voltage: 3) -5% ~ +10% nominal VDC High potential test voltage: 4) P E 2520 VAC (1s) SCCR: 5) 100kA, fuses according UL class J or L Protection category: IP 00 Overvoltage category (acc. IEC 60664-1) III Pollution degree: PD3 (according to standard IEC 60664-1) Climatic class: 25/070/21 (IEC60068-1) Cooling: External cooling 6) Overload capability: 1.6x rated current for 1 minute, once per hour Capacitive current @ no load: 200,000 hours MTTR:


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Nominal operating voltage: 3x 380 to 415 V AC Voltage tolerance range: 3x 342 to 456 V AC Operating frequency: 60 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 280 to 480 HP (209 to 358 kW) Total harmonic current distortion THDi: 2) 99% @ nominal line voltage and power Drive dc-link voltage: 3) -5% ~ +10% nominal VDC High potential test voltage: 4) P E 2160 VAC (1s) SCCR: 5) 100kA, fuses according UL class J Protection category: IP 00 Overvoltage category (acc. IEC 60664-1) III Pollution degree: PD3 (according to standard IEC 60664-1) Cooling: Internal fan cooling or external cooling 6) Overload capability: 1.6x rated current for 1 minute, once per hour Capacitive current @ no load: 200,000 hours, following maintenance plan MTTR:


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Nominal operating voltage: 3x 440 to 480 V AC Voltage tolerance range: 3x 396 to 528 V AC Operating frequency: 60 Hz ±1 Hz Network: TN, TT, IT Nominal motor drive input power rating: 350 to 600 HP (260 to 447 kW) Total harmonic current distortion THDi: 2) 99% @ nominal line voltage and power Drive dc-link voltage: 3) -5% ~ +10% nominal VDC High potential test voltage: 4) P E 2160 VAC (1s) SCCR: 5) 100kA, fuses according UL class J Protection category: IP 00 Overvoltage category (acc. IEC 60664-1) III Pollution degree: PD3 (according to standard IEC 60664-1) Cooling: External cooling 6) Overload capability: 1.6x rated current for 1 minute, once per hour Capacitive current @ no load: 200,000 hours MTTR:


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3.5 Additional electrical specifications Ecosine max passive harmonic filters general electrical specifications refer to operating altitudes up to 2000m (6600ft) above sea level.

Operation between 2000m and 4000m (6600ft and 13123ft) requires a derating for current and clear-ance according to IEC 60664-1, hereafter enclosed:

Table 19 Altitude correction factors

Remark: Do not use ecosine max passive harmonic filters in altitudes above 4000m without consulting Schaffner first.

3.6 Cable cross-section requirement 3.6.1 Power terminals

All power terminal of ecosine max filters are busbar connection, with designation -99.

The cable cross-section must be selected according the rated filter input current, the maximum cur-rent, the environment and other special requirement of the application. It should be either a stranded copper wire cable with a temperature rating of ≥75°C or higher or a busbar not smaller than the termi-nal dimensions of the filter. Recommended cable cross-section is given in Table 20, busbar terminal dimensions are given in Figure 4. The customer is fully responsible to define the most appropriate con-ductor type according to the application and ensure a proper connection of the filter.



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Table 20 Cable cross-section recommendation

Filter Power Rating

Line Cur-rent [A]

Volt-age [V]

Freq. [Hz]

Termi-nal

Line Busbar

Termi-nal

Load Busbar

Frame Size

Min. recommended cable cross-section per phase

FN3470-250-99 250 kW 376 400 50 B B S10 2x 150 mm2 2x 250 kcmil

FN3470-315-99 315 kW 475 400 50 D F S10 2x 185 mm2 2x 350 kcmil

FN3470-355-99 355 kW 538 400 50 E G S12 2x 300 mm2 2x 500 kcmil

FN3470-400-99 400 kW 608 400 50 F G L10 2x 300 mm2 2x 500 kcmil




FN3471-355-99 355 kW 538 400 50 E F S08 2x 300 mm2 2x 500 kcmil

FN3471-400-99 400 kW 608 400 50 F F L08 2x 300 mm2 2x 500 kcmil




FN3480-400-99 400 kW 501 480 50 E G S12 2x 240 mm2 2x 400 kcmil





FN3481-400-99 400 kW 501 480 50 E F S08 2x 240 mm2 2x 400 kcmil


FN3481-560-99 560 kW 709 480 50 F F L08 3x 185 mm2 2x 700kcmil

FN3482-350-99 350 HP 325 480 60 A B S10 2x 120 mm2 2x 4/0 AWG

FN3482-400-99 400 HP 374 480 60 C B S10 2x 150 mm2 2x 250 kcmil

FN3482-450-99 450 HP 418 480 60 B F S10 2x 185 mm2 2x 300 kcmil

FN3482-500-99 500 HP 475 480 60 D G S12 2x 185 mm2 2x 350 kcmil

FN3482-600-99 600 HP 561 480 60 E G L10 2x 300 mm2 2x 500 kcmil

FN3483-350-99 350 HP 325 480 60 A B S08 2x 120 mm2 2x 4/0 AWG

FN3483-400-99 400 HP 374 480 60 C F S08 2x 150 mm2 2x 250 kcmil

FN3483-450-99 450 HP 418 480 60 B B S08 2x 185 mm2 2x 300 kcmil

FN3483-500-99 500 HP 475 480 60 D F S08 2x 185 mm2 2x 350 kcmil

FN3483-600-99 600 HP 561 480 60 E F L08 2x 300 mm2 2x 500 kcmil

FN3472-280-99 280 HP 325 380 60 A B S10 2x 120 mm2 2x 4/0 AWG

FN3472-315-99 315 HP 374 380 60 C B S10 2x 150 mm2 2x 250 kcmil

FN3472-355-99 355 HP 418 380 60 B F S10 2x 185 mm2 2x 300 kcmil

FN3472-400-99 400 HP 475 380 60 D G S12 2x 185 mm2 2x 350 kcmil

FN3472-480-99 480 HP 561 380 60 E G L10 2x 300 mm2 2x 500 kcmil

FN3473-280-99 280 HP 325 380 60 A B S08 2x 120 mm2 2x 4/0 AWG

FN3473-315-99 315 HP 374 380 60 C F S08 2x 150 mm2 2x 250 kcmil

FN3473-355-99 355 HP 418 380 60 B B S08 2x 185 mm2 2x 300 kcmil

FN3473-400-99 400 HP 475 380 60 D F S08 2x 185 mm2 2x 350 kcmil

FN3473-480-99 480 HP 561 380 60 E F L08 2x 300 mm2 2x 500 kcmil



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Figure 4 Drawing of different terminal dimensions (according to Table 20)



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3.6.2 Trap disconnect jumper terminals

Cable cross section recommended for connection to the trap disconnect jumper terminals (only for configuration with this option):

Table 21 recommended and maximum cable cross section for the trap disconnect jumper terminals

Filter

Minimum recom-mended cable cross section

[mm2]

Maximum cable cross section

[mm2]

Minimum recom-mended cable cross section

USCS

Maximum cable cross section

USCS

FN3470-250-99 FN3471-250-99 FN3480-315-99 FN3481-315-99 FN3482-350-99 FN3482-400-99 FN3482-450-99 FN3483-350-99 FN3483-400-99 FN3483-450-99

50 240 AWG 1/0 (0) 500kcmil

FN3470-315-99 FN3470-355-99 FN3471-315-99 FN3471-355-99 FN3480-355-99 FN3480-400-99 FN3481-355-99 FN3481-400-99 FN3482-500-99 FN3482-600-99 FN3483-500-99 FN3483-600-99

70 240 AWG 3/0 (000) 500kcmil

FN3470-400-99 FN3470-500-99 FN3471-400-99 FN3471-500-99 FN3480-500-99 FN3480-560-99 FN3481-500-99 FN3481-560-99

95 240 AWG 4/0 (0000) 500kcmil

Stripped length 29.5±0.5mm / 1.16±0.02in with ring cable lugs crimped

3.6.3 Auxiliary terminals

Recommended cable cross section for connection to the AS-AS’ and TS-TS’ auxiliary terminal:

From 0.5mm2 / AWG 20 up to 4mm2 / AWG 12 Stripped length 10.5±0.5mm / 0.41±0.02in



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3.7 Earth terminals screw and torque Table 22 earth terminals

Earth (PE) Screw thread Screw torque value

[Nm] [lbs.in]

S08-L12 M12 20-25 177-221

3.8 Thermal protection switch specifications One choke of each type is equipped with a thermal protection switch (temperature switch). The 3 switches are connected in series to the auxiliary terminal TS-TS’. If the temperature switch reaches the nominal switching temperature (NST), the switch will open.

Table 23 thermal protection switch specifications

Contact type Normally closed (NC)

Nominal switching temperature (NST) 180°C

Resetting temperature (RST) 145°C (indication only)

Operating voltage Up to 250V AC

Rated current AC Inom 2.5A cosϕ = 1.0 1.6A cosϕ = 0.6 1.8A cosϕ = 0.4-0.5

3.9 Cabinet specifications The complete ecosine max series has been type tested and qualified using reference standard cabi-nets from the manufacturer Rittal, series VX25. Schaffner recommend using the reference cabinet from Rittal series VX25 matching the filter size selected. The filter can be integrated in any standard or customized cabinet according to the same specifications as the reference cabinets. Exact parts num-ber of the reference cabinet are listed in Table 24. Usage of a cabinet that is not according to these specifications, especially any deviations from the cooling requirement and air inlet configuration (see section 3.10) might require additional validation from the customer. Schaffner is not reliable for any de-viations in the filter specifications resulting from an improper cabinet integration.



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Table 24 Part numbers of the reference cabinets from Rittal VX25

Cabinet 800mm Cabinet 1000mm Cabinet 1200mm

Baying enclosure system VX25 Basic enclosure

8806.000 8006.000 8206.000

Support Rail 48x26mm 8617.810 8617.820 8617.830

Roof-mounted fan 1’000m/h

3140.500 3140.500 3140.500

Outlet filter Standard 323 x 323 x 25 mm

3243.200 3243.200 3243.200

Outlet filter Standard 255 x 255 x 25 mm

2x 3240.200 2x 3240.200 2x 3240.200

Side panel, screw-fas-tened, sheet steel for VX

8106.245 8106.245 8106.245

Base corner piece with base cover, front and rear, 100 mm for VX

8640.033 8640.033 8640.033

Base corner piece with base cover, front and rear, optimized design, 100 mm for VX

8640.003 8640.005 8640.007



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3.10 Cooling requirement It must be ensured that the environmental temperature is kept below 40°C with appropriate thermal management (e.g. cabinet cooling). Filter operation in environments with higher temperatures require a temperature derating.

External air flow is required in all configurations. The minimum air flow required for all filters can be found in Table 25. It is recommended to have the active cooling fans located at the top of the cabinet and air inlet located according to Figure 5 and Table 26.

Table 25 Air flow required for cooling

Frame size [m3/h] Min air volume*

CFM [ft3/min]

S08, L08 1069 629

S10, L10 1069 629

S12, L12 1069 629

*External air flow required for filter configurations without embedded ventilation. Recommended installation on top of cabinet

Note: The required inlet air flow must be provided to guarantee normal operation of the filter. Insufficient inlet air flow or blocking of air channel might cause overheating of filter compo-nents.

All ecosine max passive harmonic filters have been tested and qualified with cabinet design, presented in the following. The fan configuration below is recommended, however not mandatory if the inlet air flow can be ensured otherwise.



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Figure 5 Reference cabinet with recommended air inlet placement

Table 26 Dimensions for the recommended air inlet placement

Dimension C1 C2 C3 C4

Cabinet 800mm 70 20 70 70

Cabinet 1000mm 120 20 700 80

Cabinet 1200mm 120 20 700 130

3.10.1 Additional requirement for cooling

• To allow significant air flow, the fine dust filter foam need to be removed from the air inlet. • Cable entry at the bottom and back of the cabinet should stay open (no use of tight cable entry

system if allowed). Recommended opening is visible in Figure 6 to Figure 8.



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Figure 6 opening at the bottom and back of the cabinet (front view)

Figure 7 opening at the bottom of the cabinet (top view from inside). About 1/3 remain open.



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Figure 8 opening at the back of the cabinet. Base plinth should stay open for cables entry and cooling.



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3.11 Mechanical frame sizes All ecosine max passive harmonic filters are realized with 6 frame sizes, S08/S10/S12 and L08/L10/L12. Dimensions and footprint are provided in section 3.12.

Ecosine max passive harmonic filters are IP00 and external air cooling is needed, details are provided in section 3.8. The overview of all frame sizes is shown in Figure 9.

Figure 9 Overview of all ecosine max passive harmonic filter frame sizes



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3.12 Ecosine max passive harmonic filter footprint

Figure 10 Mechanical data of FN 3471/73/81/83

Figure 11 Mechanical data of FN 3470/72/80/82

Table 27 Dimensions of all frame sizes in mm

Frame size

W D H R S1 S2 S3 T LINE LOAD Recommended cabinet size WxDxH

S08 max. 650

max. 505

1120 380 330 230 490 13.5 255 + 10

470 + 30

800x600x2000

S10 890 max. 505

1120 370 514 n/a 280 13.5 255 + 10

240 + 30

1000x600x2000

S12 1060 max. 505

1120 370 684 n/a 28 13.5 255 + 10

230 + 10

1200x600x2000

L08 max. 680

557 1320 458 320 225 485 13.5 290 + 10

540 + 30

800x600x2000

L10 890 max. 557

1320 455 504 n/a 258 13.5 290 + 10

230 + 10

1000x600x2000

L12 1060 max. 557

1320 455 674 n/a 285 13.5 290 + 10

220 + 10

1200x600x2000



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Table 28 Dimensions of all frame sizes in inches

Frame size

W D H R S1 S2 S3 T LINE LOAD Recommended cabinet size WxDxH

S08 max.25.6 max. 19.88

44.09 14.96 12.99 9.06 19.29 0.53 10.04 + 0.039

18.5 + 1.18

31.5x23.6x78.7

S10 35.04 max. 19.88

44.09 14.57 20.24 n/a 11.02 0.53 10.04 + 0.039

9.45 + 1.18

39.4x23.6x78.7

S12 41.73 max. 19.88

44.09 14.57 26.93 n/a 11.02 0.53 10.04 + 0.039

9.06 + 0.39

47.2x23.6x78.7

L08 max. 26.8 21.93 51.97 18.06 12.60 8.86 19.09 0.53 11.42 + 0.039

21.26 + 1.18

31.5x23.6x78.7

L10 35.04 max. 21.93

51.97 17.91 19.84 n/a 11.22 0.53 11.42 + 0.039

9.06 + 0.39

39.4x23.6x78.7

L12 41.73 max. 21.93

51.97 17.91 26.54 n/a 11.22 0.53 11.42 + 0.039

8.66 + 0.39

47.2x23.6x78.8



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3.13 Filter performance Ecosine max passive harmonic filters achieve 5% THDi with 6-pulse diode rectifiers under the follow-ing condition.

| Filter is applied to rated voltage and power | THDv


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Figure 13 Power factor vs. load (diode rectifier front-ends)

Figure 14 Drive dc-link voltage vs. load (diode rectifier front-ends, with FN 3471 series and drive with 4% Ldc)

0

0.2

0.4

0.6

0.8

1

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

cosϕ

Load [%]

420

440

460

480

500

520

540

560

580

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Udc

[V]

Load [%]



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3.14 Functional diagram 3.14.1 Filter configuration

Filter terminals Line L1/L2/L3 3 busbar terminals at line side Load L1’/L2’/L3’ 3 busbar terminals at load side TS, TS’ Connecting terminals to thermal switch NC 180°C (UL-

approved) to detect overload in chokes AS, AS’ Terminal for auxiliary connection, details refer to section

8.3.7 PE Protective earth. Threaded stud with washer and nut Function blocks Chokes Power magnetic components incl. temperature switches Capacitors Power capacitors incl. discharge resistors Circuit breaker Make sure the status is “On” when install the filter

Status “On” during normal operation Investigation of the system is required when the status of the switch changed to “Off”



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3.14.2 Filter configuration -E0XXJXX

Filter terminals Line L1/L2/L3 3 busbar terminals at line side Load L1’/L2’/L3’ 3 busbar terminals at load side TS, TS’ Connecting terminals to thermal switch NC 180°C (UL-

approved) to detect overload in chokes AS, AS’ Terminal for auxiliary connection, details refer to section

8.3.7. PE Protective earth. Threaded stud with washer and nut Trap disconnect

D1, D2, D3 D1’, D2’, D3’

3 couples of terminals. For optional configurations with TDJ, wire bridges are installed for immediate operation of the filter. They allow for the connection of

| an external circuit breaker | an external circuit breaker together with a remote

control module to disconnect the trap circuit at partial load

Function blocks Chokes Power magnetic components incl. temperature switches Capacitors Power capacitors incl. discharge resistors Trap disconnect

jumper Terminals for installing circuit breaker or capacitor contactor by customers themselves



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4 Ecosine max harmonic filter schematics and working principle The base module of FN 3471, FN3473, FN 3481 and FN 3483 series contains line choke, trap choke and trap capacitor, which helps reduce THDi to 5% for motor drives with an 4% DC-link choke present.

Figure 15 Schematic of FN 3471, FN 3473, FN 3481 and FN 3483 filter series

The base module of FN 3470, FN3472, FN 3480 and FN 3482 series contains line choke, load choke, trap choke and trap capacitor, which helps reduce THDi to 5% for motor drives without DC-link choke present. The base module schematic is shown in Figure 16.

Figure 16 Schematic of FN 3470, FN3472, FN 3480 and FN 3482 filter series

General working principle of ecosine max filter base modules is shown in Figure 17.

Figure 17 Working principle of ecosine max passive harmonic filters (with load choke Lo and without)

There is either trap disconnect jumper module or trap disconnect switch module available for FN 3470/FN 3471, FN 3472/FN 3473, FN 3480/FN 3481 and FN 3482/FN 3483 filters.



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5 Filter appearance and elements Ecosine max passive harmonic filters are available in IP00 open frame, and all designed for floor-mounted installation. The compact design makes it an optimized open frame for cabinet integration. The filter is all-wired with 3 inputs and 3 outputs, which can be easily installed into standard and cus-tomized cabinet.

The appearance of the filters can be differentiated depending whether the load choke is present or not in the filter.

5.1 Mechanical design of FN3470/80/72/82 (with load choke present) The general design of FN3470/80/72/82, filters with load choke and circuit breaker module (E0XXSXX) is shown in Figure 18.

On the right side of the frame, there is trap choke Lt sitting on top of the line choke Li, and the load choke Lo is next to them. The trap capacitor Ct, and circuit breaker or trap disconnect jumper is mounted on the left side of the frame.

Switch module, namely a circuit breaker, is required in high power passive harmonic filters for safety reasons. The short circuit current of high power passive harmonic filters can go beyond 10’000A, how-ever the capacitors are only protected with failure current of max. 10’000A. Therefore, an external switch able to disconnect the capacitors automatically under overloading and short circuit conditions is mandatory to ensure the installation safety at all operation situations. When the filter is overloaded, de-pending on the overcurrent value, circuit breaker will release after a certain time. The faster and higher the current rise is, the faster will the circuit breaker release. The characteristics curve of current and tripping time and more information can be found in the circuit breaker datasheeti. In case the circuit breaker is released, the connected load must be shut down immediately and remains off until the fail-ure is investigated, and problem is solved. Once everything solved and source of issue removed, the circuit breaker can be switched on again to re-start the system.

i Online datasheet and documentation for circuit breaker 250A, 300A, 400A and 500A

https://www.schaffner.com/https://datasheet.eaton.com/datasheet.php?model=271102https://datasheet.eaton.com/datasheet.php?model=269276https://datasheet.eaton.com/datasheet.php?model=269278https://datasheet.eaton.com/datasheet.php?model=269280


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Figure 18 Design of FN3470/80/72/82 filter (Type E0XXSXX)

5.2 Mechanical design of FN3471/81/73/83 (without load choke present)

The general design of FN3471/81/73/83, filters without load choke present, and with circuit breaker module (E0XXSXX) is shown in Figure 19. On the right side of the frame, there is trap choke Lt sitting on top of the line choke Li. The trap capaci-tor Ct, and circuit breaker or trap disconnect jumper is mounted on the left side of the frame.



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Figure 19 Design of FN3471/81/73/83 filter (Type E0XXSXX)



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6 Performance estimation using SchaffnerPQS Ecosine max passive harmonic filters are included and can thus be simulated with the Schaffner Power Quality Simulator SchaffnerPQS (pqs.schaffner.com).

By using SchaffnerPQS, users can easily simulate and estimate system performance taking into ac-count the most important design requirements and system’s boundary conditions.

Simulate and estimate the performance of your selected ecosine filters with Schaffner

Power Quality Simulator SchaffnerPQS3.



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7 Filter application Ecosine max passive harmonic filters are designed to mitigate harmonic current of non-linear loads, particularly of three-phase diode-type rectifiers. Contrary to “bus-applied or PCC (Point of Common Coupling)” filters, which are being installed e.g. at the main feeder, ecosine passive harmonic filters are specifically designed to be used with either an individual non-linear load, or with a group of non-linear loads.

One advantage of load-applied filtering is the fact that the upstream power (relative to the harmonic filter) is clean, i.e. unloaded by the harmonics. This can be of vital importance when the same power bus supplies both motor drives and sensitive loads. Ecosine max passive harmonic filters are also suit-able for paralleling lower power non-linear loads on a higher power harmonic filter to improve overall system economy. In this case the total expected load power of all connected drives must match the filter.

Figure 20 Application example with multiple loads per filter

If the expected input power exceeds the rating of the largest available filter, and a custom solution is not desired, then two filters can be wired in parallel. In this mode of operation, it is mandatory to use filters with equal power ratings to ensure proper current sharing.

Warning: in case of parallel use of ecosine max filter, customer must ensure that both filters have an appropriate over current protection on the trap capacitor (same for both filter), either using the optional switch -E0XXSXX or by installing a third party switch circuit breaker using the trap disconnect jumper option -E0XXJXX.



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Figure 21 Application example with 2 filters in parallel for larger load



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8 Filter installation Please follow the simple steps below to ensure a safe and reliable filter function for many years. Please do always follow the general safety and installation guidelines provided within this document as well as relevant local, national or international standards that are applicable. Please note that the fol-lowing installation steps are applicable for all ecosine max filters; FN 3470, FN 3471, FN 3472, FN 3473, FN 3480, FN 3481, FN 3482 and FN 3483.

8.1 Step 1: Visual inspection All Schaffner ecosine max passive harmonic filters have undergone rigorous testing before they left our ISO 9001:2008 certified factories. They are packaged with great care in a sturdy container for in-ternational shipment.

However, carefully inspect the shipping container for damage that may have occurred in transit. There are two TiltWatches and one ShockWatch attached on the packaging, in case one or more of the Tilt-Watch and ShockWatch indicating a record of unacceptable tilting or shock on goods (indicator turned red partially or totally), please file a claim with the forwarder immediately before unpacking anything. If both TiltWatches and the ShockWatch are good, unpack the filter and carefully inspect for any signs of damage. Keep the shipping container for future transportation or storage of the filter.

Figure 22 Location of TiltWatches and ShockWatch

In the case of damage, please file a claim with the freight forwarder involved immediately and contact Schaffner or our local partner for support. Under no circumstances install and energize a filter with suspected transportation damage, whenever it is clearly visible or not.



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If the filter is not going to be put in service upon receipt, store within the original container in a clean, dry location, free of dust and chemicals and with respect to named temperature limits, see section 2.

8.2 Step 2: Mounting Ecosine max passive harmonic filters are best installed as close as possible to the non-linear load. Ideally, they are mounted next to the rectifier or motor drive inside the electrical cabinet or control room.

All ecosine max passive harmonic filters are designed for floor mounting installation inside a cabinet.

Inside the cabinet the filter must be place as much as possible on the left side with a clearance of about 10mm to the inner frame of the cabinet. Additionally, the customer must ensure that the filter can be taken out straight from the front door of the cabinet, depending on the cabinet reference the exact position might be adjusted accordingly.

Note:

The filter placement on the left (capacitor side) is meant to improve air cooling of the capacitor and to allow as much as possible free space on the termi-nal side for power cables or busbar connections.

Important:

In order to ensure sufficient air flow, keep a clear-ance of min.150mm above the filter to ceiling or other components inside the cabinet. The outside distance between the cabinet is not restricted as far as the accessibility is guarantee (front door can fully open). Please also ensure to comply with cool-ing requirement described in section 3.8.

Figure 23 Clearance inside cabinet



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8.2.1 Fixation

Screw hole positions for mounting the filters as indicated in Table 29:

Table 29 Dimensions of frame sizes

Frame size Drill pattern [mm]

R S1 S2

S08 380 330 230

S10 370 514 n/a

S12 370 684 n/a

L08 458 320 225

L10 455 504 n/a

L12 455 674 n/a

T = 13.5 mm for all frame sizes

All dimensions in mm; 1 inch = 25.4mm

Filters FN3471/73/81/83 in frame size S08 and L08 offer two possi-bilities of fixation points.

The preferred fixation points have a distance S1 between the screws on the terminal side and screws on the capacitor side as shown in Figure 25.

Other permitted fixation points are offered in case of difficult acces-sibility of the rear fixation points. Those permitted fixation points have a distance S2 between the screws on the terminal side and screws on the capacitor side as shown in Figure 26.

Warning: In all cases, the usage of the two fixation screws on terminal side (right side on Figure 24, Figure 25 and Figure 26) is mandatory. The usage of shorter distance than S2 between fixation points and usage of less than 4 fixation screws is forbidden and could result in damage to the product and serious injuries.

Figure 24 Fixation points for fil-ters FN 3470, FN 3472, FN

3480 and FN 3482

Figure 25 Preferred (green) and forbidden (red) fixation points for filters FN 3471, FN 3473, FN 3481 and FN 3483

Figure 26 Permitted (blue) and forbidden (red) fixation points for filters FN 3471, FN 3473,

FN 3481 and FN 3483



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8.2.2 Screws and bolts selection

Depending on the cabinet specification, the heavy load fixation sys-tem might be providing either screws/rods or nuts adapted to the specific system. For the other part of the bolts (respectively the nut or screw) Schaffner recommends zinc coated hex ribbed flange steel screws or nuts. Respect filters weight for appropriate choice of screws! Head diameters must not exceed these dimensions:

M12: d ≤24 mm

Refer to the cabinet supplier documentation for more information.

8.2.3 Filter placement:

1. Lift filter with appropriate crane using the two lifting slots (dimen-sions of the slot 20x50mm).

2. Place the filter as precisely as possible by aligning the fixation holes on the filter with the matching nuts holes or rods on the base frame.

3. Insert the 4 screws or nuts and screw them approximately 1mm before the head touch the surface.

4. Double check the proper alignment and parallel position.

5. Fix screws with appropriate torque (depending upon the material of the cabinet fixation system and local standards).

Warning: the equipment weight is ≥ 240 kg

Handling and lifting of heavy equipment must always comply with your local safety standard.

Figure 27 Location of lifting slots

d



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Danger: respect lifting angle, risk of severe dam-age

The maximum allowed angle between the lifting rope and verti-cal plan should not exceed 45°. Failing to comply might destroy the equipment and induce a risk of severe injuries.

Figure 28 Maximum angle of lifting force



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8.3 Step 3: Wiring

8.3.1 Verify safe disconnection of all line side power

Consult your local safety instructions.

8.3.2 Carefully connect protective earth (PE) cable to adequate earth potential close to ecosine filter

Use a cable with diameter of equal or bigger size as fore-seen for line/load side power cables – according to your lo-cal codes and safety instructions.

8.3.3 Connect PE cable of ecosine filter

with appropriate cable lug to threaded stud.

| torque M12: 20-25 Nm



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8.3.4 Connect ecosine main terminals to the re-spective phase on the line and load/rectifier

The main cables must have an appropriate M12 ca-ble lug. In case of busbar connections, the contact surface and hole size must be appropriate to the fil-ter busbar terminals and fitting M12 screws and bolts.

Cables must be routed from below the cabinet and vertically below each busbar terminal.

Warning: during installation of cables, clearance and creepage distance must not be shortened. Live part of cable like the cable lug must not be in contact with any other part (live part, earthed part or insulated part), additionally insulation of the cable should not touch directly any live part. This can be ensured by keeping the cable in vertical position below each termi-nal during installation of cables.

Connect the cables to the busbar as follow:

1. Connect line phase L1 to the terminal L1 2. Connect load/rectifier phase L1’ to the ter-

minal L1’ 3. Connect line phase L2 to the terminal L2 4. Connect load/rectifier phase L2’ to the ter-

minal L2’ 5. Connect line phase L3 to the terminal L3 6. Connect load/rectifier phase L3’ to the ter-

minal L3’

The appropriate torque for M12 is 20-25Nm.

Please follow section 3.6 for appropriate cable or busbar selection.

Note: Depending on the possible short circuit cur-rent the main connection wires need to be fixed very strength near to the line and load terminals.

Figure 29 Location of line and load terminals for filters FN 3470, FN 3472, FN 3480 and FN 3482

Figure 30 Location of line and load terminals for filters FN 3471, FN 3473, FN 3481 and FN 3483



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8.3.5 Install external capacitive current control

For configurations with TDJ option, thus without integrated switch (see sections 2.1 to 2.4), terminals D1- D1’, D2- D2’ and D3- D3’ are delivered with installed jumpers. This con-figuration allows to install any third party switch circuit breaker (not supplied by Schaffner) and when necessary an additional capacitor contactor (not supplied by Schaffner).

The usage of a capacitor contactor in line in the trap capaci-tor circuit allows for load dependent disconnection of the trap circuit, if needed. Therefore, capacitive current can be minimized for low load operation.

Estimation of required capacitor contactor size: see box to the right.

Warning: protection of the trap capacitor against over current is still required, it is not recommended to use the filter without any switch installed. The customer is fully responsible for any inappropriate usage of the filter.

8.3.6 Connect monitor switch TS- TS’

The monitor switch is a relay contact, which is open in ALARM state. It is constituted by a thermal switch NC 180°C (UL-approved) to detect overload of chokes. It may either be used to remotely disconnect the drive’s load via respective input of drive control (check drive manual) or as an alarm switch for system control unit.

For wire cross section recommendation see section 3.6.2.

Warning: an engaged moni-tor switch must lead to immediate load shutdown and investigation of the problem.

Circuit breaker/contactor perfor-mance estimate:

Example: FN 3470-500-99-E0XXJXX

The nominal power rating in kW multiples 20% and the grid voltage, then divided by the nominal voltage (400 V for FN 347X, 480 V for FN 348X) is the approximate reac-tive power

Switch rating =

500𝑘𝑘𝑘𝑘 ∗ 20% ∗𝑉𝑉𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑔𝑉𝑉𝑛𝑛𝑛𝑛𝑛𝑛

=

500𝑘𝑘𝑘𝑘 ∗ 20% ∗400𝑉𝑉400𝑉𝑉

= 100𝑘𝑘𝑉𝑉𝑘𝑘𝑘𝑘



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8.3.7 Connect auxiliary switch AS- AS’

For filter configuration with S option (pre-equipped with switch, see sections 2.1 to 2.4)

The auxiliary switch is a contact, which indicates state of cir-cuit breaker. It is closed under normal operation (CB on) and is open in abnormal condition (CB off). Abnormal condition can be a short circuit in the trap capacitors, overcurrent in the trap circuit, too hot ambient temperature or switch-off status in low load condition (use of motor mechanism to-gether with the circuit breaker – check relevant section in the circuit breaker manuali).

For filter configuration with J option (equipped with trap disconnect jumper for third party switch installation, , see sections 2.1 to 2.4)

The AS terminal block is installed, but not connected to any switch (empty terminal). Customer can connect any auxiliary switch of an additionally installed third party switch circuit breaker (NC, NO or other). Customer is fully responsible for the third party switch installation, wiring and usage accord-ing to the respective manual.

For wire cross section recommendation see section 3.6.2.

Warning: an engaged auxil-iary switch not resulting from a manual or remote controlled open-ing must lead to immediate load shutdown and investigation of the problem.

Figure 31 terminal for auxiliary contact connection

i Online datasheet and documentation for circuit breaker 250A, 300A, 400A and 500A

https://www.schaffner.com/https://datasheet.eaton.com/datasheet.php?model=271102https://datasheet.eaton.com/datasheet.php?model=269276https://datasheet.eaton.com/datasheet.php?model=269278https://datasheet.eaton.com/datasheet.php?model=269280


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8.3.8 Install and connect the switch remote operator

(only relevant for filter with switch option, see sections 2.1 to 2.4 and with addition of remote operator module)

The remote operator for the switch allows to control remotely the switch on order when required for the application.

The remote operator module is not provided by Schaffner and when required, it need to be bought separately. Please consult the relevant user manuali for complete installation and usage.

Warning: the switch is a protection device; its purpose is to disconnect the trap capacitor circuit in case of over-current or over-heating. Usage of the switch with or without remote operator is never in-tended for frequent manual or on order opening (e.g. NZM 3 series allows only 2000 on load openings in its lifetime, please consult the switch manualii for more in-formation). For frequent commutation, the addition of a capacitor contactor in series with the switch circuit breaker is strongly recommended. Please refer to sec-tion 10 for more details.

Figure 32 Eaton switch remote opera-tor module

i Online datasheet and documentation for remote operator

https://www.schaffner.com/https://datasheet.eaton.com/datasheet.php?model=259832


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8.3.9 Fuses

Ecosine max passive harmonic filters need external over-current protection for compliance with UL/cUL standard. Fuses and associated fuse holders must be UL listed and rated for 100kA SCCR supplies. Table 30 and Table 31 show requested fuse current ratings for UL class J/L and, where UL compliance is not mandatory, for IEC class gG. The fuse rating is independent of the supply voltage.

A system with multiple ecosine max fil-ters paralleled for a higher power load need each a separate 3-phase line side fuse block, corresponding to the re-spective filter and according to Table 30 and Table 31.

The drive’s application manual may prescribe line-side fuse protection as well, which in this case either corre-sponds to the sum of the filter fuse rat-ings or, if lower, would request separate drive fuses at its input.

An application, having one ecosine fil-tering harmonics for several drives, re-quires in any case line side fuse protec-tion of the drives as well as the correct filter protection according to Table 30 and Table 31 and section 8.3.5.

fuse

fuse

ecosine 1

ecosine 2

drive M

fuse ecosine drive Mfuse

drive Mfuse

drive Mfuse



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Table 30 Requested fuse current rating for UL class J/L and for IEC class gG

Ecosine

ecosine ecosine ecosine Fuse class J/L

Fuse class gG

All FN 3470 All FN 3471 All FN 3480 All FN 3481

Rated current

A

Rated cur-

rent A FN3470-250-99 FN3471-250-99 FN3480-315-99 FN3481-315-99 600i 630 FN3470-315-99 FN3471-315-99 FN3480-355-99 FN3481-355-99 800ii 800 FN3470-355-99 FN3471-355-99 FN3480-400-99 FN3481-400-99 800ii 800 FN3470-400-99 FN3471-400-99 FN3480-500-99 FN3481-500-99 800ii 800 FN3470-500-99 FN3471-500-99 FN3480-550-99 FN3481-550-99 1000ii 1000

i UL class J ii UL class L

Table 31 Requested fuse current rating for UL class J/L

Ecosine

ecosine ecosine ecosine Fuse class J/L

All FN 3482 All FN 3483 All FN 3472 All FN 3473 Rated cur-rent A

FN3482-350-99 FN3483-350-99 FN3472-280-99 FN3473-280-99 400i FN3482-400-99 FN3483-400-99 FN3472-315-99 FN3473-315-99 600i FN3482-450-99 FN3483-450-99 FN3472-356-99 FN3473-356-99 600i FN3482-500-99 FN3483-500-99 FN3472-400-99 FN3473-400-99 800ii FN3482-600-99 FN3483-600-99 FN3472-480-99 FN3473-480-99 800ii

i UL class J ii UL class L



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9 Filter maintenance Ecosine max passive harmonic filters described in this manual are equipped with long life components that ensure a satisfactory function for many years under normal operating conditions. Any operation under extreme conditions such as over-temperatures, overvoltage situations, polluted environments etc. reduces the life expectancy. Following maintenance recommendation will help maximizing filter lifetime.

Warnings:

High voltage potentials are involved in the operation of this product. Always remove line side power before attempting to perform maintenance and let ample time elapse for the capaci-tors to discharge to safe levels (


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9.2 Power capacitors The power capacitors supplied with the filter modules are high quality components with an expected lifetime of up to 100’000 hours (11 years). Nevertheless, their useful service life can be shortened by electrical or thermal stress beyond their specification.

Power capacitor damage may also be caused by severe abnormal supply voltage peaks (i.e. lightning – depending upon system protection) but may only be recognizable through the measurement of line side harmonics distortion. This may be checked with a modern energy meter or by regular checkup with a power quality analyzer. According to the above considerations, a 2 year inspection interval is advisable.

Note: an inspection should as well be performed after extreme overvoltage situations in the system.

9.2.1 Storage of capacitors

Up to 3 years-long storage, electrolytic capacitors can be operated without any restriction and the nominal voltage can be applied without any preliminary preparation. System reliability and life-time ex-pectancy are not affected.

On the other side, a longer (>3 years) storage of electrolytic capacitors without applying any voltage can weaken the dielectric properties because of dissolution processes. The electrolytic solution is ag-gressive, it can affect and weaken the dielectric in the timeframe between production and product commissioning. The weak points are responsible for the higher leakage current shortly after the device turn-on on site.

The residual current of electrolytic capacitors depends upon time, voltage and temperature. The resid-ual current increases after long storage without applying voltage.

The amplitude of resulting residual current during unit commissioning can be up to 10 times larger on short term. The capacitor’s residual current assumes the typical expected value at steady state for nominal voltage.

During commissioning after long storage, it is recommended to restore the dielectric characteristics by applying voltage progressively and with respect to the time frame the filters have been s

ecosine max passive harmonic filters · user and installation manual ecosine max . schaffner.com...

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